Circular Halbach array integrated using an abrasive circulating system during the ultra-precision machining of polymethyl methacrylate optical material

Abstract

A novel approach to enhancing the efficacy and surface quality of magnetic polishing involves the incorporation of a magnetic liquid circulation system for abrasive particle regeneration in conjunction with a circular Halbach array. The continuous renewal of abrasive particles within the polishing zone is realised through a conveyor belt that transports new abrasive particles into the polishing liquid solution. This formation of a continuously circulating polishing system ensures uninterrupted magnetic finishing processes and maintains stability throughout the polishing operation. This study extensively explores polishing force distribution, magnetic field distribution and abrasive grain behaviour in the polishing area facilitated by the magnetic liquid solution. The application of the proposed polishing processes to polymethyl methacrylate, an optical lens material, aims to comprehend the characteristics and validate the feasibility of the polishing method. Key influencing factors in the magnetic polishing process, including abrasive grain size, magnetic particle, polishing distance and conveyor speed to surface quantity, are examined through experimental analysis. Results of the experimental polishing processes demonstrate that the utilisation of circular Halbach arrays with circulating abrasives produces a nanometric surface finish. Even in the polishing of polymethyl methacrylate with an initial rough surface (Ra = 464.895 nm), the process achieves an ultra-fine level with Ra below 9 nm without disruption in the material polishing processes of optical lenses.